IOSR Journal of Polymer and Textile Engineering (IOSR-JPTE)

e-ISSN: 2348-019X, p-ISSN: 2348-0181, Volume 9, Issue 4 (Jul. – Aug. 2022), PP 24-33
www.iosrjournals.org

A study the effect of modifications in compact spinning

machine on the yarn quality properties
Eman Y. Abd-Elkawe
Spinning Research Department, Cotton Research Institute, Agricultural Research Center, Giza, Egypt.
Corresponding author: [email protected]

Abstract
Rieter’s company had added some modifications (The Q-Package)to compact spinning machine K44 in order to
increase the machine efficiency and obtain the best yarn quality properties. Q-Package was presented for the
first time at the ITMA 2015 in Milan. The Q-Package is the combination of new developments in the drafting
system of K44 compact spinning machine. The new K 45 is modular in design, and the total machine concept
offers maximum reliability and flexibility with up to 1632 spindles.The mill-proven Ri-Q-Draft drafting system
with pneumatically loaded guide arm and the Ri-Q-Bridge provide a sound basis for high yarn quality. The core
featureof K 45 is the compacting zone with the wear-resistant, perforated metal drum. This combination is
crucial for uniform compact yarn quality. The aim of this paper is to present the effect of modifications in the
frame of compressed spinning (K44& K45) on the physical and mechanical yarn properties. In this study, long
staple cotton variety(Super Giza 94) was used, and it was spun on three yarn counts (50s , 60s, and 80s,). The
results indicated that yarn counts (50s, 60s, and 80s,) with the same twist multiplier 4.2. for the compact
spinning system (K45) was better in evennessthin places, thick places, yarn hairiness, yarn strength and yarn
elongation at break (%) than both of normal K44 and modified K44 as a result of the change in the settings and
the evaluation of the responsible part of the compact spinning, such as the air suction, the perforated cylinder,
and the path of the twisted fiber inside the suction group, which led to great control, and then improvement was
observed.on the other hand, the irregularity innormal K44 and modified K44 compact spinning system higherin
the readings of a thin places, thick places, neps, and yarn hairiness, than in K45compact spinning system.
Key words: Compact spinning, yarn quality, K45.
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Date of Submission: 20-08-2022 Date of Acceptance: 04-09-2022
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I. Introduction
The compact spinning system appeared at the ITMA exhibition in Paris in 1999, then it began to spread
in the leading countries in the textile industry. The international modifications(Rieter, Suessen and Zinser)
producing spinning machines showed different designs for compact spinning system. All designs agreed in the
basic idea and differ in condensing unit Islam (2019).Compact spinning is a process where fiber strand drawn by
drafting system is condensed before twisting it. Compact spinning system reduces the size of the spinning
triangle to a minimum. This is achieved through a condensing of the fibers after the main draft by using a
perforated roller in combination with a suction unit. The hairiness of the yarn is thus reduced, and the tenacity is
higher when compared to ring-spun yarns. The yarn evenness is also improved. The compact was described as a
modification of the ring spinning. A lot of studies conducted on compact spinning to offer advantages and
improved quality.Kumar et al (2003) reported that Compact spinning achieved great improvement in yarn
qualityproperties and yarn structure compared to the ring spinning,Krifa and Ethridge (2003) reported that
compact spinning made it possible to produce a 50 ne carded yarn having tensile properties comparable to those
of a combed yarn spun on the conventional frame. Thisimportant potential has also been raised. Jackowski et al.
(2003) reported that low hairiness of compact yarns compared to conventional yarns has raised again the issue
of measuring hairiness and the proper interpretation of the measured values. The general consensus of opinion is
that short hairs aredesirable while long hairs are not. Celik andKadoglu(2004) result showed that Compact
spinning was superior to the ring spinning system in both of yarn strength and yarn elongation at the same twist
multiplier.In addition to, compact spinning had produced high strength and elongation yarns with low twist
factor, which had enabled an increase in production rates. El-Sayed and Sanad (2007) showed that it is possible
to use low quality cotton while maintaining yarn strength equal to that of conventional ring spun yarn with the
same twist level. It is interesting to note that the improvements in yarn strength appear to be greater for long-
staple coarse yarn count than for the extra-long staple, especially in the extra-fine count. Rashid et al
(2011)showed thatcompact spinning as some advantages suchas higher yarn strength and elongation percentage,
lowerhairiness and imperfectionscompared to conventional ring yarns.El Banna et al (2013). reported that
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 A study the effect of modifications in compact spinning machine on the yarn quality properties
Compact spun yarns had better yarn hairiness, yarn elongation percentage and yarn strength than conventional
spun yarns due to compact spinning was minimized or eliminated of spinning triangle by using air section to
condense all fibers in yarn formationyarn count and spinning system beside the yarn quality play an important
role in the efficiency and performance of spinning process.Almetwally et al(2015).in compact spinning all fibers
were incorporated into yarn body thus, compact spinning was almost eliminated spinning triangle in ring
spinning to improve yarn quality properties such as increasing yarn strength, elongation percentage, reducing
yarn hairiness and imperfections.The aim of this study to compare the physical and mechanical yarn quality
properties produced with Normalcompact,modified compact spinning frame (k44) and K 45 compact frame.

II. Materials And Methods

This study was conducted in Nile Company for fine Spinning and Waving. Rieter’sMachines were used
in different spinning stages. All samples were spun on Rieter compact spinning frame K44, modified compact
spinning (K44) and compact spinning frame K45 (Super Giza 94) was spun into three counts 50s,,60s, and 80s,
with the same twist multiplier 4.2.High Volume Instrument (HVI) was used to determine fiber properties
according to (ASTM, D: 4605-1986). All fiber tests were carried out under controlled conditions of 65 ± 2%
relative humidity and 21 ± 2∘C temperature. Fiber properties were presented in Table 1.Yarn strength (RKM)
and yarn elongation (%) were measured on the UsterTensorapid 4 (according to ASTM., D2256-02).Uster
Tester4 was used to measure Physical yarn propertieslike unevenness (CV%), Imperfection Index (thick/km,
thin/km, neps/km) and hairiness according to (ASTM, D1425-96).

Table 1. Fiber parameters for Giza94

Cotton varieties
Fiber parameters
Super Giza 94
Upper Half Mean “mm” 34.12
Uniformity Index “%” 87.21
Short Fiber Index “%” 5.57
Strength “g/tex” 42.5
Elongation “%” 6.29
Micronaire value 3.87
Maturity “%” 0.92
Reflectance (Rd) 78.63
Yellowness (+b) 9.10

The analysis of variance was determined by using a completely randomized design with four
replications and analyzed as factorial experiment according to the method described by Gomez and Gomez
(1984). All statistical procedures were conducted using the SPSS 20, statistical software package. Compact
spinning (K44) is the development of the millennium, which changed the technology of ring spinning. There
have been a lot of developments in ring spinning in the past but the development of compact spinning has
changed all aspects of advancement. This is the development, whose advantages do not limit up to the extent of
quality and productivity elevation; rather it is multidirectional and also covers the sphere of subsequent
processes of weaving, Knitting & dyeing with tremendous and significant increase in productivity. Compact
ring yarn is the best ring yarn ever spun with considerably reduced hairiness, hence numerous advantages in the
downstream processes like better fiber utilization, better I. P. I.resulting in higher work capacity. It is spinable at
lower twist than conventional ring spun yarn. The work relates to the correct selection of the apron distance clip
or spacer, used in an apron drafting system for high draft spinning, to determine the extent of opening between
the apron guide bar and the front edge of the cradle.nasir(2003).

K44 modified compact spinning system:

1. Application and compatibility
For the purpose of a correct apron nip and invariable positioning of the fiber guiding elements in the
drafting plane, the SUESSEN PINSpacer NT (Fig.1-A) has been tailor- made for the SUESSEN Active
Cradle.Therefore, the SUESSEN PIN Spacer NT (Fig. 1-B) is to be used exclusively in combination with the
Original SUESSEN Active Cradles to guarantee premium yarn values with at the same time invariable running
properties.Cradles of other manufacturers looking similar produce different apron nips and therefore wrong
setting, what inevitably affects the yarn parameters negatively! In addition, the clip connection on products other
than the original SUESSN Active cradle is notconsistently uniform, and in the worst case the position of the PIN
Spacer can change during operation.Unlike the already known one-piece PIN space, the PIN Spacer NT is made
up of two components. Basis is the spacer NT to set the apron nip, which is available with sizes from 2.25 to 5.0
mm . The correlation between spacer NT color and apron nip is the same as for the conventional SUESSEN
cardle spacers Every PIN NT can be combined with any spacer NT.Thesuessen pinspacerNt was specially

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 A study the effect of modifications in compact spinning machine on the yarn quality properties
designed for active cradle in the drafting setting of k44 machine. SuessenpinspacerNt used exclusively in
combination with the original suessen active cradlesto obtain high quality yarn properties.

(A) (B)
Fig.1. Pin Nt(1-A), spacer Nt(1-B).

The Pin NT which is available is different sizes, is just snapped on the spacer NT . the difference
between the PIN NT variants is their immersion depth into the fiber strand for the variable deflection of the
variable deflection of the fibers (Fig. 2) since the required intensity of fiber deflection by the PIN NT strongly
depends on the roving to the spun, the fiber length, fiber martial, roving twist and other factors, the spinning mill
can adjust the PIN NT precisely to the material to be spun, irrespective of the necessary cradle spacer.

Fig. 2.The difference between the PIN NT.

So it is possible – in contrast with a one- piece PIN Spacer- to optimize yarn quality values and
spinning stability indepndently of each other. In contrast to the one- piece PIN Spacer the PIN NT profile has
been changedto ensure that the fibers are forced to run under the PIN and not- by mistake- over the same. This
improves the operational reliability drastically.The correlation between Spacer NT colour and apron nip is the
same as for the standard cradle Spacers.

2- Determination of Apron Nip and PIN immersion Depth

Since the PIN NT represents an additional deflection point for the fibers in the yarn path through the
drafting system, the drafting process tends to be hampered, unlike using standard cradle spacer. We therefore
suggest that you choose a spacer NT with an apron nip which is usually one step bigger than the standard
cradle spacer and to combine them initially with the PIN NT (0.00). You may determine the optimum effect of
the PIN NT on yarn quality values and running properties by spinning trials with the various PIN s NT or by
possibly existing empirical data.Rieter’s company had added some modifications (The Q-Package)to compact
spinning machine k44 in order to increase the machine efficiency and obtain the best yarn quality properties.Q-
Package was presented for the first time at the ITMA in Milan.The Q-Package is the combination of new
developments in the drafting system of k44 compact spinning machine,for example the standard cradle has been
replaced by ACP cradle, the familiar Ri-Q-Bridge has been replaced by nose bar, the old distributor replaced by
newdistributor,the old cradle spring with 43mm cradle replaced by new type cradle spring for Package (Fig. 3,
4, 5, 6and 7 ).

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 A study the effect of modifications in compact spinning machine on the yarn quality properties

Fig.3. Active Cradle with roller, top apron, clip and pressure bar.

(A) (B)
Fig.4.Ri-Q-Bridge (A) and step-Nose Bar (B).

(A) (B)
Fig.5. Old distributor

(A) (B)
Fig.6. Old spring (A) and new spring (B).

(A) (B)
Fig.7. Old springs (A) and new spring (B).

And for correct setting of the nose bar and the cradle it is important that the plastic edge and the metal
edge of both devices are in one line Figure 8.After setting the infeed roller this set position can be used to adjust
the delivery roller by using the gauge.Raj (2020)

A) (B)
Fig.8. Correct setting of nose bar and cradle.

Take care that the distance between the bottom roller and pressure bar are min. 1mmFor further information see
attached sheet of the manual from suessen company.Fig. 9.

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 A study the effect of modifications in compact spinning machine on the yarn quality properties

Fig.9. Correct setting of delivery roller and pressure bar.

K45 compact spinning system:

The K 45 Compact for spinning machine is derived from the basic G 35 machine and the extremely
successful K 44 predecessor model with further optimization featuresand innovations. Customers benefit from a
powerful, high-quality machine incorporating diverse additional solutions in the field of spinning technology. K
45 is modular in design, and the total machine concept offers maximum reliability and flexibility with up to1632
spindlesFig.10. The mill-proven Ri-Q-Draft drafting system with pneumatically loaded guide arm and the Ri-Q-
Bridge provide a sound basis for high yarn quality. The core featureof K 45 is the compacting zone with the
wear-resistant, perforated metal drum. This combination is crucial for uniform compact yarn quality.Cotton yarn
market.

Fig. 10. K45 compact spinning frame

The purpose of this study is to present the effect of modifications in the frame of compact spinning (K44& K45)
on the physical and mechanical yarn quality properties.

III. Results And Discussion

Effect of spininng system on yarn properties
Data in Table 2 and Fig.11 showed that compact spinning K45 had highly significanteffect on all yarn
properties.K45 compact recorded better evenness (10.88), thin places (3), thick places (4), number of neps(14)
yarn hairiness(2.11) Yarn strength (25.21RKM) and Yarn elongation (6.06%). than both K44 normal compact
and K44 modify compact.while, the modified compact K44 spun yarn give higher yarn strength (25.02 RKM),
yarn elongation (5.47%) and lower thick places(12),neps (24) and yarn hairiness (2.44) than the normal
compact K44. The highestyarn unevenness (12.61), thick places (17), neps (32) and yarn hairiness (2.63), the
lowest strength (22.91 RKM) and yarn elongation (5.31%) were recorded by normal K44. It noticed that K45
compact spun yarngave better yarn strength and yarn elongation percentage and imperfections as compared with
normal compact and modify compact K44.

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 A study the effect of modifications in compact spinning machine on the yarn quality properties
Table 2. Yarn quality properties normal compact, modified and K45
Compact spinning CV Thin Thick Neps Strength
Hairiness
% -50% +50% +200 Rkm Elongation %

Normal compact K44 12.61 4 17 32 2.63 22.91 5.31

modified compact
yarn K44 12.31 6 12 24 2.44 25.02 5.47

K45 10.88 3 4 14 2.11 25.21 6.06

LSD at 5% 0.169 0.660 0.586 0.210 0.044 0.077 0.113

Normal K44
Modified K44
K45
35
30
Spinning System

25
20
15
10
5
0
CV % Thin Thick Neps Hairiness Strength Elongation
Yarn Properties

Fig.11 physical and mechanical yarn properties for normalK44, modified compact yarns and K45.

Effect of yarn count on yarn properties

The data given in Table 3and Fig.12 showed that a highly significant effect of yarn count on yarn
strength, yarnelongation, yarnunevenness (CV), thin places (-50%), thickplaces (+50%), no of neps /400m and
yarn hairiness. The highest yarn count (80s,) gave the highest yarn unevenness (12.35), thin places (6), thick
places (20) and neps (32).while, the same count gave the lowest mean values of yarn strength (22.96Rkm), and
yarn elongation (5.18%). The lowest yarn count (50s,) gave the highest yarn strength (25.73 Rkm). On the other
hand, the lowest mean values of yarn unevenness (11.32) and neps (14) and yarn hairiness (2.30) wererecorded
by 50s, yarn count.Generally, yarn strength,yarn elongation and hairiness decrease when yarns become
finer.Similar results were obtained by Abdel-Ghaffar et al (2019) who concluded that yarn strength, yarn
elongation and yarn imperfections were significantly affected by yarn count. Also, yarn hairiness was decreased
when yarn count increasing.

Table 3. Effect of yarn counts on yarn quality properties for super Giza94 long staple cotton
Count yarn CV Thin Thick Neps Strength
Hairiness
% -50% +50% +200 Rkm Elongation %
50s, 11.32 4 8 14 2.3 25.73 5.69
60s, 11.95 2 6 24 2.45 24.45 5.97
,
80s 12.35 6 20 32 2.43 22.96 5.18

LSD at 5% 0.169 0.660 0.586 0.210 0.044 0.077 0.113

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 A study the effect of modifications in compact spinning machine on the yarn quality properties

50
60
35 80
30
Yarn Count 25
20
15
10
5
0
CV % Thin Thick Neps Hairiness Strength Elongation
Yarn Properties

Fig.12 Yarn properties for Giza94 cotton variety at 50s, 60s, and 80s, yarn counts.

Data presented in Table 4 and Fig. 13showed the interaction between yarn count and compact spinning
(CxS) had significant effect on allyarnproperties.The highest mean values of unevenness (13.26 and 13.24), thin
places (9), thick places (29)andnumber of neps (48) were recorded by 80s yarn count fornormal compact. While,
the same count recorded the lowest mean values of yarn strength (21.49 RKM) for normal compact and
modified compact respectively.Yarn count 50s for K45compact recorded the lowest mean value of unevenness
(10.51) and neps (10). While, the same countfor K45 compactrecorded the highest mean value of yarn
elongation percentage (6.30%). Similar results were obtained by El Sayed (2002) and Sanad et al (2011) who
reported that yarn elongation % and yarn strength (cN/tex) were decreased significantly with increasing yarn
count. While, number of thin places,thick places and neps were increased with increasing yarn count. It noticed
that fine yarns had a lower number of fibers in the cross section than coarser yarns.

Table 4. Effect of normal compact K44, modified compact K44 and compact K45 spun yarns on
yarnquality properties for different yarn count.

Yarn Compact CV % Thin - Thick Neps Hairiness Strength Elongation %

counts spinning 50% +50% +200 RKM

Count Normal compact 12.06 1 15 19 2.75 22.71 5.16

50s K44
Modified 11.38 7 6 12 2.36 23.00 5.60
compact K44
K 45 10.51 5 2 10 1.80 24.80 6.30
Count Normal compact 12.50 1 8 28 2.80 24.20 6.00
60s K44
Modified 12.31 3 7 25 2.65 24.12 6.10
compact K44
K 45 11.04 2 4 20 1.89 25.02 5.80
Count Normal compact 13.26 9 29 48 2.34 21.49 4.76
80s K44
Modified 13.24 7 24 36 2.30 21.60 4.70
compact K44
K 45 11.08 1 7 13 2.64 25.80 6.08
LSD at 5% 0.292 1.143 1.015 0.364 0.077 0.133 0.196

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 A study the effect of modifications in compact spinning machine on the yarn quality properties

Normal K44
Yarn Strength (RKM) Modified K44
K 45

30

20

10

0
50 60 80

Fig.13- A. Effect of spinning system and yarn count on yarn Strength (RKM).

Normal K44
Yarn Elongation % Modified K44
K 45

8
6
4
2
0
50 60 80

Fig.13- B. Effect of spinning system and yarn count on yarn Elongation %.

Normal K44
Yarn CV % Modified K44
K 45

15
10

5
0
50 60 80

Fig.13- C. Effect of spinning system and yarn count on CV%.

Normal K44
Yarn Thin Places Modified K44
K 45

0
50 60 80

Fig.13- D. Effect of spinning system and yarn count on thin places.

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 A study the effect of modifications in compact spinning machine on the yarn quality properties

Normal K44
Yarn Tick Places Modified K44
K 45

30

20

10

0
50 60 80

Fig.13- E. Effect of spinning system and yarn count on Thick places.

Normal K44
Yarn Neps Modified K44
K 45

60

40

20

0
50 60 80

Fig.13- F. Effect of spinning system and yarn count on Neps.

Normal K44
Yarn Hairiness Modified K44
K 45

0
50 60 80

Fig.13- G. Effect of spinning system and yarn count on Hairiness.

IV. Conclusion
The aim of this investigation was to study the effect of modifications in the frame of compact
spinning (K44) and k45 compact spinning frame on the physical and mechanical yarn quality properties.
Results indicated that K45 compact spinning frame recorded higher yarn strength and yarn elongation than both
of normal and modified k44 compact spinning for all yarn counts. While, it recorded lower unevenness, thin
places, thick places, neps and yarn hairiness as compared with normal and modified k44 compact spinning for
all yarn counts. Generally, compact spinning frame k45 improved mechanical and physical yarn properties due
to some changes in this frame.

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Eman Y. Abd-Elkawe. “A study the effect of modifications in compact spinning machine on the yarn
quality properties.” IOSR Journal of Polymer and Textile Engineering (IOSR-JPTE), 09(04), 2022,
pp. 24-33.

DOI: 10.9790/019X-09042433 www.iosrjournals.org 33 | Page